CASE STUDY /

Ansys + ISGEC Hitachi

Zosen Limited
“Ansys’ user programmable feature (UPF) was used to create a creep
subroutine based on ASME code case 2605, which allowed us to
evaluate the creep damage of pressure equipment at elevated
temperatures in high strength chrome-moly steels.”

Balram Kalra
Assistant Manager-PED Design / ISGEC Hitachi Zosen Limited
 CASE STUDY

With the rising demand for cost-effective designs of structural components in the oil and gas
sector, manufacturers want to utilize the maximum temperature capability of the materials.
The current ASME code (Section VIII, Division 2) limits the generation of fatigue curves up to a
maximum of 371 °C. ASME Code Case 2605 is a special rule used in the industry worldwide for
fatigue evaluation of 2.25Cr-1Mo-0.25V steels at temperatures greater than 371 °C and less than
454 °C.

Utilizing the Maximum Temperature Capability

of Materials for Creep-Based Design of Pressure
Equipment

/ Challenges

Code Case 2605 proposes carrying out full inelastic analysis, such as ratcheting elastic
shakedown analysis, using the actual time-dependent thermal and mechanical loading
histograms. Treating plasticity and creep as two independent phenomena in stress
and strain calculations using spreadsheet-like applications are subject to human error
and may lead to unrealistic damage parameters. The challenge was to create a creep
subroutine capable of analysis at the higher temperatures of Code Case 2605 using
Ansys simulation solutions to increase accuracy and accelerate calculations.

Creep damage contour plot after

/ Technology Used implementing the Ansys subroutine.

Ansys MAPDL

/ Engineering Solution

With help of Ansys technical team members, ISGEC Hitachi Zosen engineers used the
user programmable feature (UPF) in Ansys MAPDL to implement a Code Case 2605
creep model. By combining user creep with standard plasticity material models already
available in Ansys solutions, they succeeded in calculating the overall creep strain and
creep damage under cyclic loading conditions at temperatures up to 454 °C.

/ Benefits

After implementing the creep subroutine for calculation of creep damage and creep
strains for chrome-moly steels, ISGEC Hitachi Zosen engineers were able to:

• Optimize the equipment weight by maximizing the material capacity at high

temperatures while ensuring that any creep damage was within the acceptable Creep strain contour plot after implementing
code limit. the Ansys subroutine.

• Drastically reduce the time required for calculation and post-processing of creep
strain and creep damage results using a seamless finite element analysis process.

• Nullify chances of human error common in manual spreadsheet calculations, which

involve many assumptions and often overestimate creep damage.

ISGEC Hitachi Zosen Limited is the market-leading manufacturer of complex pressure

vessels and heat exchanger equipment for customers all over the world. We provide
solutions for a variety of industry segments in which we are the manufacturing leaders.
We also help in reducing the scale-up risks from lab to the plant.

Ansys + ISGEC Hitachi Zosen Limited // 2

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Ansys + ISGEC Hitachi Zosen Limited // 3